Method and apparatus for electolysis-assisted generation of hydrogen

ABSTRACT

The present invention provides a method and apparatus for electrolysis-based generation of hydrogen and oxygen to enhance combustion. A hydrogen generating apparatus comprises an electrolysis cell, the electrolysis cell electrically connected to a power source, an outlet for directing effluent gases from the electrolysis cell, and a scrubber for using a scrubbing medium to remove contaminants from the effluent gas flow. In another option, a first mesh electrode may be situated within the electrolysis cell and electrically connected to a power source, a second mesh electrode may be situated within the electrolysis cell and electrically connected to the power source, and a membrane may be situated between the first mesh electrode and the second mesh electrode which may be immersed within the aqueous solution.

BACKGROUND OF THE INVENTION

The present invention relates generally to the generation of hydrogen and/or oxygen, and, more particularly, to an electrolysis cell for supplying gaseous fuel additives to enhance combustion in a combustion engine. The present invention also may be used to generate hydrogen and/or oxygen to be stored for use as a fuel or other purpose.

Electrolysis is a well-known process whereby an electric current is passed through an aqueous solution. The electric current splits the water molecules, releasing hydrogen and oxygen gasses which may be directed to the air intake of an engine.

Hydrogen may be mixed with gasoline vapor and air to enhance the efficiency of internal combustion engines. When the mixture of such gases ignites, the hydrogen distributed throughout the mixture burns first and contributes to an optimum combination of the remaining vaporized fuel.

Often, electrolysis to produce hydrogen and/or oxygen from water uses a basic electrolyte, such as a 20-30% aqueous solution of potassium hydroxide (KOH). A disadvantage of such a method of electrolysis is environmental contamination. KOH can be present in the fuel/air mixture, leading to KOH and KOH by-products being dumped into the atmosphere via engine exhaust. Additionally, KOH is caustic, unnecessarily damaging engine components and even degrading the electrodes used in the electrolysis apparatus.

Thus it would be advantageous to use a method of apparatus to generate hydrogen and/or oxygen that minimizes contamination by KOH or any other harmful substance.

As can be seen, there is a need for an improved apparatus and methods for generating hydrogen and/or oxygen for enhancing combustion, for example, a method that effectively and efficiently removes KOH from effluent gases or a method that uses water without KOH.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a hydrogen generating apparatus comprises an electrolysis cell, the electrolysis cell electrically connected to a power source; an outlet for directing effluent gases from the electrolysis cell, the electrolysis cell containing an electrolysis zone and a reservoir zone, an aqueous solution stored within the electrolysis cell, and a mesh electrode situated within the electrolysis zone.

In another aspect of the present invention, a method for generating hydrogen comprises delivering electricity to an electrolysis cell, the electrolysis cell comprising a first mesh electrode, separating the electrolysis cell into an electrolysis zone, and a reservoir zone, generating hydrogen and oxygen by electrolysis of an aqueous solution contained within the electrolysis zone, directing generated hydrogen from the electrolysis cell, and introducing the generated hydrogen into an internal combustion engine.

In a further aspect of the present invention, a hydrogen generating apparatus comprises a cylindrical electrolysis cell, the electrolysis cell electrically connected to a power source, the electrolysis cell comprising an electrolysis pack, the electrolysis pack comprising a electrolysis zone and a reservoir zone, a separator situated between the electrolysis zone and the reservoir zone, an aqueous solution stored within the electrolysis zone and the reservoir zone, a first mesh electrode situated within the electrolysis zone, an inlet for refilling aqueous solution into the electrolysis cell, and an outlet for directing effluent gases from the electrolysis cell.

In yet another aspect of the present invention, a hydrogen generating apparatus comprises an electrolysis cell, the electrolysis cell electrically connected to a power source; an outlet for directing effluent gas flow from the electrolysis cell; an aqueous solution stored within the electrolysis cell; and a scrubber for using a scrubbing medium to remove contaminants from the effluent gas flow.

In still another aspect of the present invention, a method for generating hydrogen comprises delivering electricity to an electrolysis cell, the electrolysis cell electrically connected to a power source; generating hydrogen and oxygen by electrolysis of an aqueous solution contained within the electrolysis cell; directing effluent gas flow from the electrolysis cell; scrubbing contaminants from the effluent gas flow with a scrubbing medium; and introducing the effluent gas flow into an internal combustion engine.

In a still further aspect of the present invention, a hydrogen generating apparatus comprises an electrolysis cell; an aqueous solution stored within the electrolysis cell; a first mesh electrode situated within the electrolysis cell and electrically connected to a power source; a second mesh electrode situated within the electrolysis cell and electrically connected to the power source; a membrane situated between the first mesh electrode and the second mesh electrode and immersed within the aqueous solution; an inlet for refilling aqueous solution into the electrolysis cell; and an outlet for directing effluent gases from the electrolysis cell to the engine.

What is needed is an efficient method of electrolytic hydrogen generation for enhancing internal combustion without releasing caustic chemicals, such as potassium hydroxide to avoid excessive waste, improve the environment, and provide a low maintenance system.

These and other aspects, objects, features and advantages of the present invention, are specifically set forth in, or will become apparent from, the following detailed description of an exemplary embodiment of the invention when read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a vehicle using a hydrogen generating apparatus, according to an embodiment of the present invention;

FIG. 2 is a plan view of the hydrogen generating apparatus of FIG. 1;

FIG. 3 is a view, in section, of an electrolysis cell, according to another embodiment of the present invention;

FIG. 4 is a view, in section, of a scrubber for removing contaminants in effluent gas, according to yet another embodiment of the present invention;

FIG. 5 is a view, in section, of an electrolysis cell, according to yet another embodiment of the present invention;

FIG. 6 is a view, in section of electrode material, with a membrane, according to an embodiment of the present invention;

FIG. 7 is an elevation view of mesh material for an electrode, according to an embodiment of the present invention;

FIG. 8 is a flow diagram of a method for generating hydrogen, according to still another embodiment of the present invention; and

FIG. 9 is a flow diagram of another method for generating hydrogen, according to a still further embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

The present invention involves admixing hydrogen and/or oxygen into a fuel/air mixture to enhance combustion. The present invention will be described below using the example of a diesel-fueled truck. However, it should be understood that the present invention is also useful for other applications needing enhanced combustion, such as passenger automobiles, heavy equipment, buses, locomotives, marine engines, military vehicles, aircraft, spacecraft, power generation turbines, stationary generators, and the like. The present invention may also be used to produce hydrogen and/or oxygen to be used as fuel or fuel additives.

The present invention avoids polluting the environment with caustic substances, like KOH, which also may corrode engine parts and other apparatuses. For example, one or more mesh electrodes, membrane electrodes, or mesh electrodes combined with membrane electrodes may be used to efficiently and effectively break water into hydrogen and oxygen for enhancing combustion. The electrodes may be constructed of suitable metals, such as stainless steel, nickel, platinum, palladium, and alloys thereof. Also, the electrodes may be constructed of durable materials with coatings of suitable metals, such as nickel, platinum, palladium, and alloys thereof. In another example, electrolyte components, like KOH, may be removed from effluent gas flows by scrubbing with a scrubbing medium, such as the electrolyte itself.

Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout several views, which are not necessarily drawn to scale, and more particularly referring to FIG. 1, the present invention provides a hydrogen generating apparatus 30 mounted on a vehicle (such as a diesel tractor-trailer type) 10 having an engine 20. A gas intake tube 40 may be in fluid communication between the hydrogen generating apparatus 30 and the engine 20, such that effluent gas from the hydrogen generating apparatus 30 may be directed to the engine 20.

FIG. 2 is a plan view of the hydrogen generating apparatus 30 of FIG. 1. A power supply 12, such as an automotive battery, may be used to provide electrical current through positive pathway 60 and negative pathway 70, to operate electrolysis within an electrolysis cell 50. Water and/or electrolyte solution (such as an aqueous solution of calcium hydroxide, sodium hydroxide, potassium hydroxide, mixtures thereof, and the like) 80 may be fed into the electrolysis cell 50 via conduit 84 and/or inlet 90. A reservoir 82 may be used for accumulation and/or overflow of electrolyte solution 80, which may be fed via inlet 86. The electrolysis cell 50 produces hydrogen and oxygen. Hydrogen, oxygen, or both hydrogen and oxygen may be ported out of the electrolysis cell 50 via a gas conduit 120.

The electrolyte solution 80 may exit the electrolysis cell 50 through an electrolyte bleed 92. A flow of the electrolyte solution 80 may be pumped onward and travel through an electrolyte flow tube 96. It may be desirable to split the flow of electrolyte solution 80 into more than one flows, such as a first electrolyte flow 97 and a second electrolyte flow 98. A scrubber 122 may be used for scrubbing contaminants from the effluent gas flow (such as hydrogen and/or oxygen) with a scrubbing medium, perhaps with an aqueous solution, such as the electrolyte solution 80. An electrolyte recycle conduit 126 may serve for delivering the scrubbing medium to the electrolysis cell 50. For example, recovered scrubbing medium, such as recovered electrolyte solution, may flow through a recycle outlet 124 for travel through the electrolyte recycle conduit 126 for recirculation into the electrolysis cell 50. Gas flow (containing hydrogen, oxygen, and/or mixtures thereof) may continue via an outlet 110 as gaseous effluent 100. The gaseous effluent 100 may be mixed into a fuel/air mixture for combustion in an engine (such as engine 20 as shown in FIG. 1).

The gaseous effluent 100 may be sent to storage for future use as a fuel or other uses. For example, a facility may use the present invention to generate and accumulate hydrogen, oxygen, and/or mixtures thereof to supply passenger automobiles, industrial equipment, buses, locomotives, marine engines, military vehicles, aircraft, spacecraft, power generation turbines, stationary generators, and the like.

FIG. 3 is a view, in section, of a hydrogen generating apparatus 30, according to another embodiment of the present invention. The hydrogen generating apparatus 30 may comprise an electrolysis cell 50. A separator 132 may be used to divide or separate the electrolysis cell 50 into a reservoir zone 128 and an electrolysis zone 130. An electrolyte 52 is contained within the electrolysis cell 30. The electrolyte 52 may be present in the reservoir zone 128 and/or the electrolysis zone 130. The electrolyte 52 may reach an electrolyte level 129, which may be greater than, less than, or equal to a predetermined refill level 131 wherein whenever the electrolyte level 129 is at the predetermined refill level 131, the electrolysis cell 50 is able to operate for a minimum operating period. A level indicator 134 may be used to monitor electrolyte level 129 in relation to the predetermined refill level 131.

The electrolyte 52 may be an aqueous solution, water, or any other suitable electrolyte for generating hydrogen and/or oxygen. An electrolysis pack 142 may be situated within the electrolysis zone 130. The electrolysis pack 142 may have therein a first electrode 138 and a second electrode 140.

A port 144 may be used to permit electrolyte flow between the reservoir zone 128 and the electrolysis zone 130. A temperature indicator 136 may be used to detect the temperature of the electrolyte 52.

A scrubber 122 (such as the scrubber described above regarding FIG. 2) is shown in FIG. 4, according to yet another embodiment of the present invention. The scrubber 122 may comprise a scrubber housing 123 wherein a scrubbing medium may be used to remove contaminants from a gas flow. The contaminants (such as entrained KOH) may be removed by creating intimate contact between one or more flows of the scrubbing medium and a flow of the effluent gas (such as spraying the scrubbing medium into the flow of the effluent gas). Scrubbing may be performed with more than one flow of the scrubbing medium. For example, one or more electrolyte flows 97, 98 may be sprayed into the flow of the effluent gas traveling within gas conduit 120. The scrubbing medium may a flow of the aqueous solution used as an electrolyte solution 80 in electrolysis cell 50 (shown in FIGS. 2 and 3). The direction of flow of the scrubbing medium may be cross-current to the direction of flow of the effluent gas.

The scrubber 122 may comprise a scrubbing nozzle 125 for creating intimate contact between a flow of the scrubbing medium and a flow of the effluent gas. The flow of the scrubbing medium may be sprayed into the flow of the effluent gas. The direction of flow of the scrubbing medium may be cross-current to the direction of flow of the effluent gas. For example, the direction of flow of the scrubbing medium may be substantially perpendicular (such as from about 70 degrees to about 110 degrees) to the direction of flow of the effluent gas. After the liquid and gaseous flows merge in the scrubbing nozzle 125, residue 146 (such as KOH) may exit the scrubbing nozzle 125 via a scrubbing orifice 127 for collection at the bottom of the scrubber housing 123. Stripped gas, may exit through the scrubbing orifice 127, depleted of residue 146, may travel through outlet 110 as gaseous effluent 100. As recovered solution 150 accumulates within the scrubber housing 123, electrolyte solution may be recovered via an electrolyte recycle conduit 126 for recycle into the electrolysis cell 50 (shown in FIGS. 2 and 3).

An electrolysis cell 152 in FIG. 5 is an example of an electrolysis cell that may be suitable for the present invention, especially when it is desirable to avoid using KOH or other caustic substances for electrolysis. The electrolysis cell 152 is capable of electrolysis using only water (such as distilled water) as an aqueous solution, as the membrane, along with charged members, effects separation of the aqueous solution into hydrogen and oxygen.

The electrolysis cell 152 may comprise a container 154 for holding aqueous solution 156 (such as water) and an inlet 159 for refilling aqueous solution 156 into the electrolysis cell 152. The electrolysis cell 152 may have a solution level 158 wherein the aqueous solution 156 sufficient to perform electrolysis. The container 154 may be made of any suitable, durable, inert material, such as polymer-based materials. The container 154 may be in any suitable shape, such as a rectangular box, a cylinder, a conical shape, or any other suitable shape.

Electrical charge may be supplied by a power source 160 (such as a battery). The electrical charges may be supplied along current feeds 162, 164 to a first mesh electrode 170 and a second mesh electrode 172. The first mesh electrode 170 and the second mesh electrode 172 may be situated within the electrolysis cell 152 and electrically connected to the power source 160. A membrane 174 may be situated between the first mesh electrode 170 and the second mesh electrode 172 and immersed within the aqueous solution 156.

A gas outlet 166 may serve for directing gas effluent 168 (such as gas flow containing hydrogen, oxygen, or mixtures thereof) from the electrolysis cell 152 to be used, such as for intake in an engine or storage for future use.

The membrane 174 causes oxygen and hydrogen to separate from liquid water when the membrane 174 is situated between charged plates, such as first mesh electrode 170 (such as an anode for producing oxygen) and second mesh electrode 172 (such as a cathode for producing hydrogen) to form a membrane electrode assembly 175. The membrane 174 may be of the type that is used in PEM (proton exchange membrane) systems. For example, the membrane 174 may be an ion-exchange membrane, such as a perfluorosulfonic cation-exchange membrane, Nafion, commercially available from DuPont. The membrane 174 may act as a catalyst for the separation of water into oxygen and hydrogen.

The mesh electrodes 170, 172 may be made from one or more portions of durable materials, such as carbon steel, stainless steel, polymer, nickel, platinum, palladium, ruthenium, iridium, manganese, cobalt, chromium, and the like. As shown in FIG. 6, the membrane electrode assembly 175 may comprise the membrane 174 sandwiched between porous mesh electrodes 170,172. The membrane 174 may have a first side 176 and a second side 178. The membrane 174 may comprise an active coating on the first side 176 and/or the second side 178, such as in a binary membrane system. The active coating may serve to enhance electrolysis. The first mesh electrode 170 may have a different composition from the second mesh electrode 172. For example, first side 176 may contain suitable substances, such as copper, platinum, nickel, palladium, and alloys thereof. Second side 178 may contain suitable substances, such as copper, platinum, nickel, palladium, and alloys thereof. Sides 176,178 may be treated by coating with the aforementioned substances and/or impregnating with the aforementioned substances. In one manner, powdered platinum, in solution, may be impregnated into the surface of one or more sides 176,178 of the membrane 174.

Exemplary mesh material 180 is shown in FIG. 7. As alternative to porous mesh material, electrodes 170,172 may comprise titanium fiber or slivered titanium (or other suitable metal). For example, titanium foil may be shredded, pressed onto a board or sheet, heat treated, and further processed to obtain an electrode material with large sum total active surface area or great porosity.

The present invention may provide a method 200 for generating hydrogen and/or oxygen, as shown in FIG. 8. The method 200 of generating hydrogen and/or oxygen does not necessarily occur in the sequence expressly presented herein or in FIG. 8. In fact, the method of the present invention may be practiced in any sequence of steps. The method 200 may comprise a step 210 delivering electricity to an electrolysis cell, the electrolysis cell electrically connected to a power source. A step 220 may comprise generating hydrogen and oxygen by electrolysis of an aqueous solution (such as water or KOH solution) contained within the electrolysis cell. Another step 230 may comprise directing effluent gas from the electrolysis cell. A further step 240 may comprise scrubbing contaminants from the effluent gas flow with a scrubbing medium (such as the aqueous solution). Introducing the effluent gas flow into an internal combustion engine may comprise step 250. A step 260 may comprise directing generated oxygen from the electrolysis cell and introducing the generated oxygen into an internal combustion engine. Creating intimate contact between a flow of the scrubbing medium (such as water or the aqueous solution) and a flow of the effluent gas may comprise a step 270. A step 280 may comprise spraying the scrubbing medium into the flow of the effluent gas. A step 290 may comprise scrubbing with more than one flow of the scrubbing medium.

It can be seen in FIG. 9 that the present invention also provides a method 300 for generating hydrogen, for example, for an internal combustion engine. The method 300 of generating hydrogen and/or oxygen does not necessarily occur in the sequence expressly presented herein or in FIG. 9. In fact, the method of the present invention may be practiced in any sequence of steps. The method 300 may comprise a step 310 of delivering electricity to an electrolysis cell, the electrolysis cell comprising a first mesh electrode, a second mesh electrode, and a membrane situated between the first mesh electrode and the second mesh electrode. A step 320 may comprise generating hydrogen and oxygen by electrolysis of an aqueous solution contained within the electrolysis cell. The method 300 may also comprise a step 330 of directing generated hydrogen from the electrolysis cell. Another step 340 may comprise Introducing the generated hydrogen into an internal combustion engine. In step 350, the method 300 may comprise directing generated oxygen from the electrolysis cell and introducing the generated oxygen into an internal combustion engine.

The method 300 for generating hydrogen may also comprise a feature wherein the electrolysis cell has a predetermined refill level wherein the aqueous solution at the predetermined refill level enables the electrolysis cell to operate for a minimum operating period.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.

Furthermore, a method may be performed in one or more sequences other than the sequence presented expressly herein. 

1. A hydrogen generating apparatus, comprising: an electrolysis cell, the electrolysis cell electrically connected to a power source; an outlet for directing effluent gas flow from the electrolysis cell; an aqueous solution stored within the electrolysis cell; and a scrubber for using a scrubbing medium to remove contaminants from the effluent gas flow.
 2. The hydrogen generating apparatus of claim 1, wherein the scrubber comprises a scrubbing nozzle for creating intimate contact between a flow of the scrubbing medium and a flow of the effluent gas.
 3. The hydrogen generating apparatus of claim 2, wherein the flow of the scrubbing medium is sprayed into the flow of the effluent gas.
 4. The hydrogen generating apparatus of claim 3, wherein the direction of flow of the scrubbing medium is cross-current to the direction of flow of the effluent gas.
 5. The hydrogen generating apparatus of claim 4, wherein the direction of flow of the scrubbing medium is substantially perpendicular to the direction of flow of the effluent gas.
 6. The hydrogen generating apparatus of claim 1, wherein the scrubbing medium is a flow of the aqueous solution.
 7. The hydrogen generating apparatus of claim 2, comprising more than one flow of scrubbing medium.
 8. The hydrogen generating apparatus of claim 1, further comprising an electrolyte recycle conduit for delivering the scrubbing medium to the electrolysis cell.
 9. A method for generating hydrogen, comprising: delivering electricity to an electrolysis cell, the electrolysis cell electrically connected to a power source; generating hydrogen and oxygen by electrolysis of an aqueous solution contained within the electrolysis cell; directing effluent gas flow from the electrolysis cell; scrubbing contaminants from the effluent gas flow with a scrubbing medium; and introducing the effluent gas flow into an internal combustion engine.
 10. The method for generating hydrogen of claim 9, further comprising directing generated oxygen from the electrolysis cell and introducing the generated oxygen into an internal combustion engine.
 11. The method for generating hydrogen of claim 9, further comprising creating intimate contact between a flow of the scrubbing medium and a flow of the effluent gas.
 12. The method for generating hydrogen of claim 11, further comprising spraying the scrubbing medium into the flow of the effluent gas.
 13. The method for generating hydrogen of claim 11, wherein the direction of flow of the scrubbing medium is cross-current to the direction of flow of the effluent gas.
 14. The method for generating hydrogen of claim 11, wherein the scrubbing is performed with more than one flow of the scrubbing medium.
 15. The method for generating hydrogen of claim 9, wherein the scrubbing medium is a flow of the aqueous solution.
 16. The method for generating hydrogen of claim 9, wherein the electrolysis cell has a predetermined refill level wherein the aqueous solution at the predetermined refill level enables the electrolysis cell to operate for a minimum operating period.
 17. A hydrogen generating apparatus, comprising: an electrolysis cell; an aqueous solution stored within the electrolysis cell; a first mesh electrode situated within the electrolysis cell and electrically connected to a power source; a second mesh electrode situated within the electrolysis cell and electrically connected to the power source; a membrane situated between the first mesh electrode and the second mesh electrode and immersed within the aqueous solution; an inlet for refilling aqueous solution into the electrolysis cell; and an outlet for directing effluent gases from the electrolysis cell to the engine.
 18. The hydrogen generating apparatus of claim 17, wherein the first membrane is coated on one side with a substance in the group consisting of nickel, platinum, titanium, and alloys thereof.
 19. The hydrogen generating apparatus of claim 17, wherein the electrolysis cell has a predetermined refill level wherein the aqueous solution at the predetermined refill level enables the electrolysis cell to operate for a minimum operating period. 